Arcuate mounting bracket and fabrication system

ABSTRACT

An arcuate mounting bracket fabrication system includes a powered roller conveyor for receiving blanks to be formed into arcuate connection brackets. A roll form assembly received the blanks and includes a plurality of roll forming dies for incrementally bending portions of blanks to form straight flanges terminating in lips. An entry assembly carried by the powered roller conveyor positions the blanks entering the roll form assembly. An arcuate flange forming apparatus for forming arcuate flanges in the roll formed blank receives roll formed blanks from a transfer mechanism.

FIELD OF THE INVENTION

This invention relates to post and beam construction.

More particularly, the present invention relates to brackets and plates for fastening beams to posts.

BACKGROUND OF THE INVENTION

In the field of construction, many structures are built using post and beam construction. These include buildings, sheds, shade structures, parking structures and the like. Post and beam construction in specific instances employs a post (column) extending vertically upwards and a T-beam lying across the top end of the upright post and fixed in place. With respect to metal frame structures, the post and beam are often fastened by using plates overlying the vertical sides at the upper end of the post and extending upwardly to overlie the sides of the beam positioned above the post. These plates can be welded or bolted to the post and beam. While effective, using welding for attachment of the beam to the post causes a great deal of labor and requires continued manipulation of the beam to insure the desired position relative the post. This increases cost and reduces quality. By using plates, the junction between the post and beam is strengthened somewhat, but the length of the beam overlying the post is limited in length depending on the gauge of the metal and type of metal used.

It would be highly advantageous, therefore, to remedy the foregoing and other deficiencies inherent in the prior art.

An object of the present invention is to provide an arcuate connection bracket for fastening a T-beam to a post.

Another object of the present invention is to provide an arcuate connection bracket providing substantial strength to the beam, allowing for greater length or less inherent strength.

Yet another object of the present invention is to provide a forming system for the fabrication of arcuate connection brackets.

SUMMARY OF THE INVENTION

Briefly, to achieve the desired objects and advantages of the instant invention, provided is an arcuate mounting bracket fabrication system. The arcuate mounting bracket fabrication system includes a powered roller conveyor having a front end for receiving blanks to be formed into arcuate connection brackets, and a back end. A roll form assembly has a front end coupled to the back end of the powered roller conveyor and includes a plurality of roll forming dies carried from the front end to a back end for incrementally bending portions of blanks to form straight flanges terminating in lips. An entry assembly is carried by the back end of powered roller conveyor adjacent the roll form assembly for positioning blanks entering the roll form assembly. An arcuate flange forming apparatus for forming arcuate flanges in the roll formed blank is positioned by the blank receiving area. A transfer mechanism for transferring the roll formed blank to the arcuate flange forming apparatus for forming.

The arcuate flange forming apparatus includes a frame having an upper portion and a lower portion. A top die assembly is carried by the upper portion of the frame and includes a top pad having an upper surface attached to the upper portion of the frame, a lower surface, a back edge and a front edge. A die holder has an upper surface slidably engaging the lower surface of the top pad, a back edge, a front edge and a lower surface. A lip die has an arcuate back edge, a front edge engaging the back edge of the die holder, and a top surface partially slidably engaging the lower surface of the top pad. A bead die is carried by and underlies the die holder and the lip die. The bead die includes an arcuate back edge, a front edge, a lower surface, and an arcuate bead channel formed in the lower surface parallel to and spaced apart from the arcuate back edge. A first actuating motor is attached to the front edge of the die holder for moving the die holder in a forward and backward reciprocating movement. A bottom die assembly is carried by the lower portion of the frame, partially underlying the top die assembly. The bottom die assembly includes a forward die assembly including a pressure plate having an arcuate rearward edge and reciprocally moveable vertically between a raised position and a lowered position by a second actuator motor. The pressure plate is positioned underlying and adjacent the lower surface of the bead die in the raised position. A rearward die assembly includes a pressure plate having an arcuate forward edge parallel to and spaced from the arcuate rearward edge of the forward die assembly. The rearward die assembly is reciprocally moveable vertically between a raised position and a lowered position by a third actuator motor. The pressure plate is positioned rearward of and above the lip die in the raised position. A horizontal actuating motor is coupled to the pressure plate of the rearward die assembly for reciprocally movement of the pressure plate of the rearward die assembly horizontally between a forward position and a rearward position with the rearward die assembly in the raised position.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which:

FIG. 1 is a plan view of an arcuate connection bracket according to the present invention;

FIG. 2 is a perspective view of the arcuate connection bracket of FIG. 1;

FIG. 3 is a plan view of a forming system according to the present invention, for forming the arcuate connection bracket;

FIG. 4 is a is a side elevation view of the forming system of FIG. 3;

FIG. 5 is a front view of the arcuate flange forming system according to the present invention;

FIG. 6 is a sectional side view of the arcuate flange forming apparatus of FIG. 5;

FIG. 7 is a top view of the arcuate flange forming apparatus illustrating positioning of a blank inserted therein;

FIG. 8 is a perspective view of a top die assembly;

FIG. 9 is a top view of the top die assembly of FIG. 8;

FIG. 10 is a side view of the top die assembly of FIG. 8;

FIG. 11 is a sectional end view of the top die assembly of FIG. 8 FIG. 12 is a top view of the bottom die assembly;

FIG. 13 is a sectional side view of the bottom die assembly of FIG. 12; and

FIG. 14 perspective view of the bottom die assembly of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to FIGS. 1 and 2 which illustrate an arcuate connection bracket generally designated 10. Arcuate connection bracket 10 is preferably fabricated of steel, but it is understood that other metals and alloys such as aluminum and the like can be employed. Arcuate connection bracket includes a body 12 having an upper edge 14 with opposing ends 15 and 16, and a lower edge 17 having opposing ends 18 and 19. Lower edge 17 is shorter in length than upper edge 14, spaced apart therefrom, and positioned intermediate opposing ends 15 and 16 of upper edge 14. A side edge 20 of body 12 extends generally perpendicularly from end 15 of upper edge 14 and terminates in an end 22. An arcuate edge 24 of body 12 extends from end 22 of side edge 20 and terminates at end 18 of lower edge 17. A side edge 26 of body 12 extends generally perpendicularly from end 16 of upper edge 14 and terminates at an end 27. An arcuate edge 28 of body 12 extends from end 27 of side edge 26 and terminates at end 19 of lower edge 17. A flange 30 extends perpendicularly from upper edge 14 between opposing ends 15 and 16, terminating in a lip 32. A flange 34 extends perpendicularly from arcuate edge 24 between ends 22 and 18, terminating in a lip 36. A flange 38 extends perpendicularly from arcuate edge 28 between ends 27 and 19, terminating in a lip 39. Flanges 30, 34 and 38, with associated lips, provide rigidity and strength to arcuate connection bracket 10. Further adding strength and rigidity are beads 40 and 42 formed in body 12 and extending parallel and spaced from upper edge 14 between side edges 20 and 26. An arcuate bead 44 is formed in body 12 extending parallel to and spaced from arcuate edge 24. An arcuate bead 46 is formed in body 12 extending parallel to and spaced from arcuate edge 28.

Turning now to FIGS. 3 and 4, a fabrication system generally designated 50 is illustrated. Fabrication system 50 includes a powered roller conveyor 52 receiving blanks 53 to be formed into arcuate connection brackets 10. A laser station 55 can be used to perform all of the cuts to form blanks 53. Typically, sheet steel is provided from a roll of sheet steel to laser station 55 for cutting. Blank 53 is cut and fed onto powered roller conveyor 52. Powered roller conveyor 52 conveys blank 53 to a roll form assembly 58. Blank 53 is aligned properly with roll form assembly 58 by an entry assembly 60. Entry assembly 60 has guides 62 to adjust and insure an accurate position of blank 53 when fed into roll form assembly 58 by powered roller conveyor 52. Roll form assembly 58 includes a plurality of roll forming dies 64 which incrementally bend portions of blank 53 to form flange 30 terminating in lip 32 and strengthening beads 40 and 42. Roll formed blank 53 is deposited from roll form assembly 58 onto a second powered conveyor 66 and positioned to be placed in an arcuate flange forming apparatus 70. In the preferred embodiment, roll formed blank 53 is moved from second powered conveyor 66 to arcuate flange forming apparatus 70 by use of a robot arm 72. This allows for precise positioning of blank 53. One skilled in the art will understand that other methods, such as by hand, can be employed.

Referring now to FIGS. 5 and 6, arcuate flange forming apparatus 70 is illustrated. Arcuate flange forming apparatus 70 includes a frame 72 supporting a top die assembly 74 and a bottom die assembly 76. Top die assembly 74 is carried by an upper portion 78 of frame 72 and bottom die assembly 76 is carried by a lower portion 79 of frame 72, partially underlying top die assembly 74. With additional attention to FIG. 7, blank 53 is inserted into a front side of arcuate flange forming apparatus 70 between top die assembly 74 and bottom die assembly 76 with one of arcuate edge 24 and 28 being inserted and formed, then removed and the other of arcuate edges 24 and 28 being inserted and formed. The removal and insertion of blank 53 is preferably accomplished by robotic arm 72, but can be accomplished manually. For purposes of clarity of the present description, the terms “front” and “forward” are used for the direction toward the inserted blank 53 and the side of elements towards the inserted blank 53. The terms “back” and “rearward” are used for the direction away from the insert direction of blank 53 and the side of elements positioned away from the insert direction of the inserted blank 53, as can be seen in FIG. 7.

Turning now to FIGS. 8-11, top die assembly 74 includes a top pad 80 having an upper surface 82 attached to upper frame 78 (FIGS. 5 and 6), a lower surface 84, a back edge 86 and a front edge 88. A downwardly directed stop portion 90 extends from lower surface 84 at front edge 88. A die holder 92 has an upper surface 94 that slidably engages lower surface 84 of top pad 80. Die holder 92 includes a back edge 94, a front edge 95 and a lower surface 96. A lip die 100 has an arcuate back edge 102 and a front edge 104 engaging back edge 94 of die holder 92. A top surface 106 of lip die 100 can be reciprocally moved under top pad 80 with the reciprocal movement of die holder 92. A bead die 110 is carried underlying die holder 92 and lip die 100 and is reciprocally movable therewith. Bead die 110 includes an arcuate back edge 112, a front edge 114 and a lower surface 116. An arcuate bead channel 118 is formed in lower surface 116 parallel to and spaced apart from arcuate back edge 112. An actuating motor 120 is attached to front edge 95 of die holder 92. Actuating motor 120 is preferably a hydraulic cylinder, but it will be understood that other types of motors, which can move die holder 92 in a forward and backward reciprocating movement, such as pneumatic, electric, and the like, can be used.

With specific reference to FIGS. 10 and 11, FIG. 10 illustrates die holder 92 moved to the full backward or engaged position. In the engaged position, back edge 102 of lip die 100 and back edge 112 of bead die 110 are spaced backwards from back edge 86 of top pad 80 to expose an engagement portion of upper surface 106 of lip die 100. FIG. 11 illustrates die holder 92 moved to the full forward or release position. In the release position back edge 102 of lip die 100 and back edge 112 of bead die 112 are spaced closer to back edge 86 of top pad 80 eliminating the exposure of the engagement portion of upper surface 106 of lip die 100. The purpose for this movement will be described presently.

Referring now to FIGS. 12-14, bottom die assembly 76 is illustrated. Bottom die assembly 76 includes a forward die assembly 130 and a rearward die assembly 132. Forward die assembly 130 incudes a pressure plate 134 reciprocally moveable vertically between a raised position and a lowered position by an actuator motor 136. As can be seen with specific reference to FIG. 14, two hydraulic cylinders act as the actuator motors in the preferred embodiment. It will be understood that other types of motors, which can move pressure plate 134 between the raised and the lowered position, such as pneumatic, electric, and the like, can be used. Pressure plate 134 includes an upper surface 137 and an arcuate rearward edge 138. An extrusion punch 140 is carried by upper surface 137 extending the length thereof, spaced apart from and parallel to arcuate rearward edge 138. Extrusion punch 140 extends upwardly slight from upper surface 137 and is positioned underlying top die assembly 80 such that extrusion punch 140 is received within bead channel 118 thereby forming strengthening bead 44 and 46 in blank 53, as will be described presently. In the raised position, upper surface 137 is positioned underlying and adjacent to lower surface 116, thereby capturing a portion of blank 53 therebetween.

Rearward die assembly 132 incudes a pressure plate 142 reciprocally moveable vertically between a raised position and a lowered position by an actuator motor 143. As can be seen with specific reference to FIG. 13, at least one hydraulic cylinder acts as the actuator motor 143 in the preferred embodiment. Pressure plate 142 includes a wiping die 144 carried by a die pad 146. Wiping die 144 includes a top surface 150 and a front wiping surface 152. Front wiping surface 152 has an arcuate shape positioned parallel to and spaced apart from arcuate rearward edge 138 of front die assembly 130. A wiping die bracket 154 underlies the die pad 146 and is acted upon by actuator motor 143 to raise and lower pressure plate 142. Wiping die bracket additionally supports a horizontal actuating motor 156 to reciprocally move pressure plate 142 horizontally between a forward position and a rearward position. As can be seen with specific reference to FIG. 14, two hydraulic cylinders act as the actuator motors in the preferred embodiment. It will be understood that other types of motors, which can move pressure plate 142 between the forward position and the rearward position, such as pneumatic, electric, and the like.

In operation, one of arcuate edge 24 and 28 of blank 53 is inserted into arcuate flange forming apparatus 70 between top die assembly 74 and bottom die assembly 76. When correctly positioned, for example, edge 24 overlies front die assembly 130 and extends over rearward die assembly 132. Front die assembly 130 and rearward die assembly 132 are both raised until front die assembly presses blank 53 against 116 of upper die assembly 80. In this movement, extrusion punch 140 deforms the material of blank 53 into arcuate bead channel 118, forming strengthening bead 44. At this point front die assembly 130 has moved to the raised position and stops. Rearward die assembly 132 continues moving upwardly with front wiping surface 152 of wiping die 144 sliding past back edge 102 of lip die 100 and back edge 112 of bead die 112. At this point in the process lip die 100 and bead die 112 are in the engaged position. As front wiping surface 152 of wiping die 144 sliding past, arcuate edge 24 of blank 53 is bent upwardly parallel to back edge 102 of lip die 100 and back edge 112 of bead die 112 with a portion extending upwardly therepast. Rearward die assembly reaches the raised position when the bottom of pressure plate 142 is positioned above top surface 106 of lip die 100. At this point in the process, pressure plate 142 is moved to the forward position, bending the remaining portion of edge 24 parallel to top surface 106 of lip die 100. In this manner, arcuate flange 34, lip 36 and arcuate strengthening bead 44 are all formed in blank 53. To release blank 53, forward die assembly 130 and rearward die assembly 132 are each moved to the lowered position, and die holder 92 is moved to the full forward or release position. In the release position back edge 102 of lip die 100 and back edge 112 of bead die 112 are disengaged from lip 36, fully releasing blank 53. This process is repeated for arcuate edge 46 to form arcuate flange 38, lip 39 and arcuate strengthening bead 46. Robotic arm 72 engages blank 53, removes it from arcuate flange forming apparatus 70, turns it to the proper orientation and inserts arcuate edge 46 for forming. Once formed, the completed arcuate connection bracket 10 is removed and disposed as desired.

Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof, which is assessed only by a fair interpretation of the following claims.

Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: 

1. Arcuate mounting bracket fabrication system comprising: a powered roller conveyor having a front end for receiving blanks to be formed into arcuate connection brackets, and a back end; a roll form assembly having a front end coupled to the back end of the powered roller conveyor, the roll form assembly including a plurality of roll forming dies carried from the front end to a back end for incrementally bending portions of blanks to form straight flanges terminating in lips; an entry assembly carried by back end of powered roller conveyor adjacent the roll form assembly for positioning blanks entering the roll form assembly; an arcuate flange forming apparatus for forming arcuate flanges in the roll formed blank; and a transfer mechanism for transferring the roll formed blank to the arcuate flange forming apparatus.
 2. The arcuate mounting bracket fabrication system as claimed in claim 1 wherein the transfer mechanism is a robotic arm.
 3. The arcuate mounting bracket fabrication system as claimed in claim 1 further comprising a laser station to cuts blanks from sheet metal positioned proximate the front end of the powered roller conveyor.
 4. The arcuate mounting bracket fabrication system as claimed in claim 1 wherein the roll form apparatus further includes a plurality of roll for forming dies incrementally forming strengthening beads in the blank.
 5. The arcuate mounting bracket fabrication system as claimed in claim 1 wherein the arcuate flange forming apparatus comprises: a frame having an upper portion and a lower portion; a top die assembly carried by the upper portion of the frame, the top die assembly comprising: a top pad having an upper surface attached to the upper portion of the frame, a lower surface, a back edge and a front edge; a die holder having an upper surface slidably engaging the lower surface of top pad, a back edge, a front edge and a lower surface; a lip die having an arcuate back edge, a front edge engaging the back edge of the die holder, and a top surface partially slidably engaging the lower surface of the top pad; a bead die carried by and underlying the die holder and the lip die, the bead die includes an arcuate back edge, a front edge, a lower surface, and an arcuate bead channel formed in the lower surface parallel to and spaced apart from the arcuate back edge; and a first actuating motor attached to the front edge of the die holder for moving the die holder in a forward and backward reciprocating movement; a bottom die assembly carried by the lower portion of the frame, partially underlying the top die assembly, the bottom die assembly comprising: a forward die assembly including a pressure plate having an arcuate rearward edge and reciprocally moveable vertically between a raised position and a lowered position by a second actuator motor, the pressure plate positioned underlying and adjacent the lower surface of the bead die in the raised position; a rearward die assembly including a pressure plate having an arcuate forward edge parallel to and spaced from the arcuate rearward edge of the forward die assembly, the rearward die assembly reciprocally moveable vertically between a raised position and a lowered position by a third actuator motor, the pressure plate positioned rearward of and above the lip die in the raised position; and a horizontal actuating motor coupled to the pressure plate of the rearward die assembly for reciprocally movement of the pressure plate of the rearward die assembly horizontally between a forward position and a rearward position with the rearward die assembly in the raised position.
 6. The arcuate flange forming apparatus as claimed in claim 5 wherein the forward die assembly further comprises an arcuate extrusion punch carried by an upper surface of the pressure plate of the forward die assembly and extending a length thereof, the arcuate extrusion punch spaced apart from and parallel to the arcuate rearward edge of the pressure plate of the forward die assembly and extending upwardly from the upper surface of the pressure plate of the forward die assembly and positioned underlying the top die assembly such that the arcuate extrusion punch is received within the bead channel with the forward die assembly in the raised position.
 7. The arcuate flange forming apparatus as claimed in claim 5 wherein the pressure plate of the rearward die assembly including a wiping die carried by a die pad, the wiping die includes a top surface and a front wiping surface having an arcuate shape and positioned parallel to and spaced apart from the arcuate rearward edge of the pressure plate of the front die assembly.
 8. The arcuate flange forming apparatus as claimed in claim 7 further including a wiping die bracket underlying the die pad and acted upon by the third actuator motor and carrying the horizontal actuating motor.
 9. Arcuate flange forming apparatus comprising: a frame having an upper portion and a lower portion; a top die assembly carried by the upper portion of the frame, the top die assembly comprising: a top pad having an upper surface attached to the upper portion of the frame, a lower surface, a back edge and a front edge; a die holder having an upper surface slidably engaging the lower surface of top pad, a back edge, a front edge and a lower surface; a lip die having an arcuate back edge, a front edge engaging the back edge of the die holder, and a top surface partially slidably engaging the lower surface of the top pad; a bead die carried by and underlying the die holder and the lip die, the bead die includes an arcuate back edge, a front edge, a lower surface, and an arcuate bead channel formed in the lower surface parallel to and spaced apart from the arcuate back edge; and a first actuating motor attached to the front edge of the die holder for moving the die holder in a forward and backward reciprocating movement; a bottom die assembly carried by the lower portion of the frame, partially underlying the top die assembly, the bottom die assembly comprising: a forward die assembly including a pressure plate having an arcuate rearward edge and reciprocally moveable vertically between a raised position and a lowered position by a second actuator motor, the pressure plate positioned underlying and adjacent the lower surface of the bead die in the raised position; a rearward die assembly including a pressure plate having an arcuate forward edge parallel to and spaced from the arcuate rearward edge of the forward die assembly, the rearward die assembly reciprocally moveable vertically between a raised position and a lowered position by a third actuator motor, the pressure plate positioned rearward of and above the lip die in the raised position; and a horizontal actuating motor coupled to the pressure plate of the rearward die assembly for reciprocally movement of the pressure plate of the rearward die assembly horizontally between a forward position and a rearward position with the rearward die assembly in the raised position.
 10. The arcuate flange forming apparatus as claimed in claim 9 wherein the forward die assembly further comprises an arcuate extrusion punch carried by an upper surface of the pressure plate of the forward die assembly and extending a length thereof, the arcuate extrusion punch spaced apart from and parallel to the arcuate rearward edge of the pressure plate of the forward die assembly and extending upwardly from the upper surface of the pressure plate of the forward die assembly and positioned underlying the top die assembly such that the arcuate extrusion punch is received within the bead channel with the forward die assembly in the raised position.
 11. The arcuate flange forming apparatus as claimed in claim 9 wherein the pressure plate of the rearward die assembly including a wiping die carried by a die pad, the wiping die includes a top surface and a front wiping surface having an arcuate shape and positioned parallel to and spaced apart from the arcuate rearward edge of the pressure plate of the front die assembly.
 12. The arcuate flange forming apparatus as claimed in claim 11 further including a wiping die bracket underlying the die pad and acted upon by the third actuator motor and carrying the horizontal actuating motor.
 13. Arcuate mounting bracket comprising: a body having an upper edge with a first end and a second end and a lower edge having a first end and a second end, the lower edge being shorter in length than the upper edge, spaced apart therefrom, and positioned intermediate the first end and the second end of the upper edge; a first side edge of the body extending generally perpendicularly from the first end of the upper edge and terminating in an end; a first arcuate edge of the body extending from the end of the first side and terminating at the first end of the lower edge; a second side edge of the body extending generally perpendicularly from the second end of the upper edge and terminating in an end; a second arcuate edge of the body extending from the end of the second side edge and terminating at the second end of the lower edge; a flange extending perpendicularly from the upper edge between the first end and the second end thereof and terminating in a lip; a first arcuate flange extending perpendicularly from the first arcuate edge and terminating in a lip; and a second arcuate flange extending perpendicularly from the second arcuate edge and terminating in a lip.
 14. The arcuate mounting bracket as claimed in claim 13 further comprising: a pair of parallel strengthening beads formed in the body and extending parallel and spaced from the upper edge; a first arcuate bead formed in the body 12 and extending parallel to and spaced from the first arcuate edge; and a second arcuate bead formed in the body and extending parallel to and spaced from the second arcuate edge. 